I think it is a complicated way to enjoy cycling
however, it works well.
This punter had two carbon bikes fail with no crashes, let us be realistic, the paranoia for lower grams numbers is now well and truly into total silliness.
I recently rode a few big name carbon bikes and it was like riding a bike with solid rubber tyres, there was no give at the bars. One can do the lift and thump down test with hands pressed down on the handle bars with the same wheel swapped over to the different bikes and good grief. Some are like granite. They handle like total crap around any corners other than on billiard table like road, skating So called engineers don't know what they don't know.
If that is all you have ridden then one does not know what a nice bike feels like. Like eating Maccas, if you think that is food......................
Any how, Cadenzia lug set, Columbus tubes, Columbus steel fork, Di2 grouppo, 32 hole wheels, 28mm tyres.

Dazza

07-31-2014, 04:12 PM

a lathe is a beautiful thing
file file sand sand
cook
file file sand sand
yeah
that will work

Dazza

07-31-2014, 04:18 PM

not about cartons or pictures to fill out nothing
or Sun Glass adverts

bicycle metal work from my workshop for those who may find it interesting :p

bravo sir! please continue to share, as a hobby-builder myself it is always fascinating to see process photos from a true master of the craft!

Dazza

08-01-2014, 03:53 PM

The Australian Broadcasting Corporation , Aunty gives me brain food while I work for 11 hours on Thursday

Dazza

08-01-2014, 04:10 PM

I hooked the logic circuits of a Bambleweeny 57 Sub-Meson Brain to an atomic vector plotter suspended in a strong Brownian Motion producer ( a nice hot cup of tea)

I looked at other builders with cables hooking and looping about the FD and I thought, why?
With steel you can make lots of nice details, enter stage left "the lathe"
then a few test pieces and 1.8mm is the bush thickness, shhh, don't tell any one.
Made a bush (flat surface for the grommet sit correctly against)
I chopped up one of Richards Sachs old Suntour look alike braze on mounts.
They are a nice part. File grind and braze
Bingo

Some thing like this may have been done before or similar, it would make sense if others have arrived at the same place, but I have not seen or noticed before.

Dazza

08-01-2014, 04:13 PM

that the pics are enjoyed and useful
Thank you for the kind compliments

Ahneida Ride

08-01-2014, 10:29 PM

Nice pictorial tutorial !!!!!!!!!! :banana:

soulspinner

08-02-2014, 12:51 PM

Love this stuff...

54ny77

08-06-2014, 08:32 AM

lovin' the photo series, keep 'em coming!

Dazza

08-06-2014, 03:47 PM

I am not a fan of sharp cornered plates near the lugs
so round reinforcement plate with round corners to reduce the stress riser
Correct flat surface and 1.75mm flat surface on the inside to ensure the Shimano 6mm Grommet sits in correctly. Curved surface for the grommet to sit on is errrr, not the best.

and it is stainless so the rust will not start around the edges

The chain stay entry is the one with most heart ache.
I can see the need for designing and producing castings but Shimano will sneeze next year and change the grommet size etc

Dazza

08-06-2014, 04:59 PM

The important thing is the hole in the CS to be as small as possible
and the foot print of the reinforcement is such that a failure will never occur
Holes in tubes are never to be taken lightly
I see builders poking tubes through top tubes, chainstays and fork blades and brazing with no reinforcements, they will have failures.
The boss has to allow for the grommet to set correctly, thus 4.2mm about the tube surface and allow the newer longer Shimano Di2 wire thread through with ease.

I started with 3D CAD drawings, then a lump 28.6mm round stainless bar and started the cutting

Dazza

08-06-2014, 05:05 PM

I attacked the Cadenzia lugs, to make them look different.
Each frame I make is a bit different than the last one.
I like lugs with curves

firerescuefin

08-06-2014, 08:56 PM

Love the details. Thank you for taking the time to shoot and share. A real treat.

soulspinner

08-07-2014, 08:54 AM

Man those lugs are ridiculous (my teenager explained this is the highest compliment)...........

jghall

08-07-2014, 02:28 PM

Sweet. Certainly one of the names on my bucket list.

Dazza

08-08-2014, 03:08 PM

Working long days.
I start at 5.30am (still dark outside this morning as I type at 6.00am)
finish at 5.00 - 6.00pm each evening.
Working this weekend, 4-5 sets of wheels to build.
No steam railway work this week but for the AGM this arvo.
However Ginger and I are off to go camping for 10 days next week at Goomburra National Park. Going bush is the best thing.

Bike to pack and ship
Ergo to pack and ship
wheels to build
Need to finish my model engineering workshop off (built next door) and get stuck into my 5" gauge steam locos
while playing on the full size railway (also chairman of Rosewood Railway Management committee)
Better to wear out than rust out

I am pleased that many enjoy my pictures, that is cool.
Thank you all for the kind comments

thinpin

08-08-2014, 10:37 PM

Strewth!

nismosr

10-23-2014, 07:12 PM

Wow how much does it cost for a frame something like this?

Dazza

10-23-2014, 07:26 PM

Wow how much does it cost for a frame something like this?

best to email direct

Sorry I have not kept up to date with pics from the workshop
I sort of work two jobs, one pays for the potatoes
and the other is for fun with a heritage railway with real steam locomotives :)
I promise to try in the weeks and months to come to post pics

soulspinner

10-24-2014, 06:45 AM

Thanks for these. This type of workmanship is becoming lost. Some of us appreciate this level of detail (and the work that went into it). Give us more when you can, always great to see.

Dazza

10-24-2014, 03:59 PM

Still at paint with Joey Cosegrove but here is the rest the pics

Dazza

10-24-2014, 04:01 PM

More pics from Bob's bike build

Dazza

10-24-2014, 04:05 PM

Another batch

Dazza

10-24-2014, 04:08 PM

Bench test
and no pics till this one is back from Joey's paint magic

Dazza

03-19-2015, 03:40 PM

Cobby has a story on Veloaficionado (http://veloaficionado.com/llewellyn-bicycles-custom-cadenzia-di2-shimano-dura-ace/)

I knew Cobby 30 years ago when he would blow me off his wheel in the final at races like the Musselwell to Tambrook. He rode off Scratch in the interstate classics, I rode off Chopping block in NSW.
then we crossed paths in recent years when he moved to Brisbane.

OtayBW

03-21-2015, 08:47 AM

Very nice! Well done. A real beauty :banana:

Dazza

03-25-2015, 02:39 AM

Waiting for the 165 cranks to arrive
then the full assembly
Quick happy snap

http://farm8.staticflickr.com/7598/16737935639_72ab8580d2_z.jpg

I blended the stem lug points and then Joey does his paint magic, I like the colours Christine selected
https://farm9.staticflickr.com/8750/16304141573_9b2d2fa2f5_z.jpg

I machine the stem spacer from stock alloy to the correct size and then it is painted with the frame.
https://farm8.staticflickr.com/7602/16304161503_c4a6ca8aea_z.jpg

I blend the head lugs together with tangents to the shorelines. Takes longer but looks nicer that way compared to just fitting them together.
https://farm8.staticflickr.com/7619/16898219676_8db7bca7a3_z.jpg

One detail that is super for those outside of the Land Down Under
1.00 USD = 1.29076 AUD
US Dollar ↔ Australian Dollar
:banana:

Only a couple of years ago it was .90 USD = 1.00 AUD:eek:

Dazza

03-28-2015, 06:49 PM

I remake the Swedish made Sogreni bell to bracket to fit 31.8mm handle bars.
Machine and made from stainless steel and brazed to the Sogreni brass mount.
Stainless steel screws are used to make the sweetest looking bell around with a sweet ring.

make some more bits on the beautiful thing (28 year old lathe)
and a jiggy thingy sort of bobsie

https://farm6.staticflickr.com/5478/11972173936_214bc5df04_z.jpg

https://farm3.staticflickr.com/2891/11971353685_9db1ac4266_z.jpg

more cooking

https://farm6.staticflickr.com/5532/11971636003_27985a329e_z.jpg

the pin hole is in the original brass casting

https://farm3.staticflickr.com/2806/11972169926_93e3c76d11_z.jpg

https://farm8.staticflickr.com/7291/11972168876_b452343fac_z.jpg

I have done a couple of these now

https://farm8.staticflickr.com/7459/11971349075_d0feda065b_z.jpg

Need silver handle bars eh!

https://farm4.staticflickr.com/3760/11971749514_6d11e39637_z.jpg

I turn the edge smooth on the lathe and polish off, just to make it slippery smooth

https://farm4.staticflickr.com/3670/11971748134_b07fcf46ac_z.jpg

Of course in stainless

https://farm4.staticflickr.com/3786/11971344745_6698832621_z.jpg

soulspinner

03-29-2015, 07:15 AM

I remake the Swedish made Sogreni bell to bracket to fit 31.8mm handle bars.
Machine and made from stainless steel and brazed to the Sogreni brass mount.
Stainless steel screws are used to make the sweetest looking bell around with a sweet ring.

Down under it's these two watching the master toil to ensure the standards are met.

And these are the level of details they see in every frame.

My Custodian is a lifetime bike!

Thanks again Dazza!

Dazza

03-31-2015, 04:35 PM

Down under it's these two watching the master toil to ensure the standards are met.

And these are the level of details they see in every frame.

My Custodian is a lifetime bike!

Thanks again Dazza!

Thank you Peter, It pleases me to see you enjoying your Llewellyn.

Dazza

04-01-2015, 08:05 PM

Esolutions is having a melt down, they have emergency maintenance now messages.
email forwarding has been an ongoing problem for 6 months which was fixed but fails time and time again
My website is down yet again

If any one had been trying to contact me using
darrell@llewellynbikes.com
don't

Please use

llewellynbikes@powerup.com.au

Jesper64

04-03-2015, 10:01 PM

Darrell, thanks for taking the time to take all these pictures, most appreciated. Really interesting to see how it's all done.

Love these process photos! Makes me want to take a stab at building a frame, then I realize it would look about 3% as good, haha.

dubrat

01-09-2016, 01:41 PM

Hey Dazza care to share anymore details on your new model you outed the disturbs for in FNL

Dazza

02-10-2016, 05:47 PM

Will do
Stay tuned

soulspinner

02-11-2016, 06:09 AM

Will do
Stay tuned

:beer:

Dazza

03-21-2016, 10:43 PM

He has a set of looooooooooooooooooong pins under him
and a not so supple back so the frame is such to meet his contact points,
so it will not have the classic proportions the art critics will desire, after all, Duncan has to be able ride it.
Duncan's Crescendo is about to be packed and shipped to Victoria via Mr TNT.

https://c2.staticflickr.com/2/1668/25880325431_a9f870e6fe_b.jpg

https://c2.staticflickr.com/2/1613/25674726530_dfef1d7aca_b.jpg

https://c2.staticflickr.com/2/1508/25949384946_1b01513f69_b.jpg

https://c2.staticflickr.com/2/1468/25854478082_a15602814b_b.jpg

https://c2.staticflickr.com/2/1599/25854517872_9d40a31b98_b.jpg

https://c2.staticflickr.com/2/1634/25674744040_872d40eb3f_b.jpg

https://c2.staticflickr.com/2/1643/25949412676_6972f2ebe2_b.jpg

https://c2.staticflickr.com/2/1467/25975284975_3a865783f6_b.jpg

https://c2.staticflickr.com/2/1581/25854524042_e6096b14fa_b.jpg

https://c2.staticflickr.com/2/1526/25949411786_f65b20b04c_b.jpg

54ny77

03-22-2016, 08:01 AM

as usual, craftsmanship and artistry.

that paint looks as deep as an ocean trench.

:beer:

soulspinner

03-22-2016, 09:00 AM

:hello::beer:

evo111@comcast.net

03-22-2016, 10:40 PM

Tied and soldered very old school! Great attention to detail as always!:D

beeatnik

03-23-2016, 12:03 PM

Dazza, looks proper to this art casualty. Guessing the owner is 6'5" plus.

Dazza

03-23-2016, 03:21 PM

Dazza, looks proper to this art casualty. Guessing the owner is 6'5" plus.

not sure of his height, yep, he would be around 6' 5"
his saddle height is 850mm (metric world here)

Peter B

03-23-2016, 08:54 PM

'round these parts he'd be known as the jolly green giant!

don compton

03-23-2016, 10:04 PM

Are those Grand Bois Cerf's, 700x28?

Dazza

03-27-2016, 03:06 PM

are those grand bois cerf's, 700x28?

yes

AllanVarcoe

04-14-2016, 03:48 PM

Damn! Amazing quality and attention to detail!

I love seeing how people do all of the little things that make their bikes unique.

Thanks for sharing.

rsoffar

12-27-2016, 01:36 PM

oh wow, the details just get even better!

macaroon

01-15-2017, 05:01 PM

Steady on lad! Crackin' work

pncguy

02-23-2017, 12:11 PM

I've read through this thread - and all the others - and I am mesmerized. When Dazza says thanks for the kind words it is almost as if he doesn't realize what beauty his hands have wrought.

Dazza, your work is masterful and has singlehandedly turned my heart toward lugged bikes. Of course, not all are as beautiful as yours. I hope you are around for a long time making works of art like these and helping people enjoy their cycling.

Definitely my "next" bike, if there is ever another custom. :beer:

weisan

02-23-2017, 09:45 PM

https://c2.staticflickr.com/2/1668/25880325431_a9f870e6fe_b.jpg

hey look at that! The proportions looked like my japanese mini-velo. :D